Oak Ridge National Laboratory and Mississippi State University’s Advanced Composite Institute have been selected to assist in the research and technical development of production workflows using thermoplastic and thermoset deposition.
JuggerBot 3D LLC, an industrial 3D printer OEM, announced today the selection of key technical partners for a hybrid additive manufacturing (AM) project through the Air Force Research Laboratory (AFRL). Mississippi State University’s Advanced Composites Institute (ACI) and Oak Ridge National Laboratory (ORNL) have been chosen as technical partners for their expertise in Fused Granulate Fabrication (FGF) and Direct Ink Writing (DIW) composite manufacturing.
These organizations will collaborate to develop reliable process parameters for consistent material deposition, demonstrating the steps needed to produce production tooling for composite manufacturing.
This $4 million congressional award, announced in February of 2024 and funded by the Office of the Under Secretary of Defense for Research and Engineering Manufacturing Technology (OSD(R&E)), aims to advance large-scale hybrid additive manufacturing in order to enable the production of faster, less expensive tooling critical to the Defense and Aerospace industry. The project involves the development of a system integrating two-part resin and pellet-fed material extrusion technologies, processing performance-grade thermoplastic polymers and advanced thermoset resin inks, including epoxies and vinyl esters. The system is designed to reach build volumes of 360 ft³, showcasing critical process controls synonymous with JuggerBot 3D’s additive technologies. Throughout the project, set to be completed in December 2025, several phases of technology development will occur, from system development to comprehensive modeling and advanced tool path development.
As the project progresses into system development and validation, the expertise of ORNL and MSU ACI is crucial. Oak Ridge National Laboratory, known for advancing innovative additive manufacturing technologies, including Fused Granulate Fabrication (AKA pellet-fed 3D printing), has been selected to support advanced tool path generation software. This selection builds on previous Collaborative Research and Development Agreements (CRADAs) focused on sophisticated AM processing, such as JuggerBot 3D’s Bead Characterization System (BCS) and other competencies found in the JuggerBot 3D Material Card. In an industry first, ORNL and JuggerBot 3D will enhance slicing software and printer hardware to process thermosets independently and simultaneously with thermoplastics. As a result, JuggerBot 3D will also develop and integrate thermoset Material Cards.
Mississippi State University’s Advanced Composites Institute, a respected leader in pioneering composite technologies, will lead system-level validation. This process, which includes rigorous material testing and assessment (MT&A), ensures the effectiveness of the established process parameters for both thermoset and thermoplastic materials. Highlighting the project’s impact, Hunter Watts, Research Engineer at MSU’s ACI, explained that “In an industry that demands rapid results, transitioning from a six-figure investment in a mold that takes 12-18 months to produce to one that takes only a few weeks at a fraction of the cost is a significant enabler across the U.S.'” Watts also highlighted the collaborative spirit of the project, noting, “We are excited about the opportunity to partner with JuggerBot 3D and everyone involved to accelerate not only this technology but also the adoption of this groundbreaking manufacturing process.”
While technical development is key, the project’s true value lies in its long-term impact. By accelerating production timelines for limited life aircraft and reducing costs, this initiative will empower the Aerospace and Defense sectors to meet evolving demands with unmatched precision. By enhancing manufacturing capabilities, these innovations will support the warfighter at the speed of battle, offering parts designed to withstand high duress. As a result, the technologies developed, and the data collected will allow the additive production of medium and large-scale aerospace tools and secondary structural components.
About JUGGERBOT 3D
JuggerBot 3D is an additive manufacturing OEM specializing in large-format systems capable of processing performance materials. We design and build advanced 3D printing solutions that meet our customers’ criteria for performance, reliability, and value. JuggerBot 3D proudly manufactures its systems in Youngstown, Ohio.
